Folding box machine



Jan. 6, 1953 T. R. BAKER Erm. 2,624,248 FOLDING Box MACHINE Filed Dec. 28, 194e 4 sheets-sheet 1 m um M ATTORNEY:

Jan.' 6, 1953 T. R. BAKER r-:rAL

FOLDING Box MACHINE 4 Sheets-Sheet 2 Filed D66. 28, 1948 IN V EN TORS Fig. Z

M m M MW m M A TTOR/VL' YA Jan. 6, 1953 T. R. BAKER Erm. mmm@ Box MACHINE 4 Sheets-Sheet 4 Filed DSG. 28, .1948

Fig. 4

y JNVENToRs M le. www.

M www ATToR/vf Patented Jan. 6, 1953 Thomas R. Baker,

rIa'gemlarm, vSan Mateo, Calif.,

Machine Co.,

-Bemss-Jason Calin, a partnership Sunnyvale, and J.

San Francisco,

. 4 Claims.

This inventionvrel'ates to improvements in folding box machines Iofthe type V'in'w-hich a flat, or nearly fiat blank of foldable sheet material, for example paperboard, is'forced throughv a folding die by `a plunger, whereby the -blankfis fo'lded into hollow box form.

The invention "offers particular advantages if applied'to those imachine's of the aforementioned general class which, in addition to folding the blank during its vpassage through the die, valso perform a lockingyoperation ontheblank to lock certain blankportions, suchas'walls, panels, tabs, or flaps together, `so Lthauithese blank portions thereafter remain 'in lbox for-ming position without extraneous connecting means such as adhesive, staples, rivets, or'thelike.

However, the invention is not limited Ain its application 'to machines for the glueless assembly of folding boxes, but'offer'sfmany advantages if applied to die and plunger machines for making glued boxes.

In the production of folding boxes it is necessary after completion 'of a runo'f boxes of aparticular size 1or style to rent and readjus't the machine for a new run'of va box'o'f different size or style. Such .retting and readjustm'ent involves the 'installation of a die and plunger of vdii-ferent size, and in addition anex'chang'e.orreadjustment of the magazine in :which 'the flat 'blanks `are stored. Generally it is also `'necessary "to 'change or adjust the feeding 'mechanism which Afeeds blanks from the magazine tothe die.

t is easily seen :that the folding rof a box blank at Iprecisely the proper lines not only re-v quires correct 'adjustment ofthe plunger with respect to the die, but `also a delivery of the blank to the die in precisely 'that'position 'which leads to the folding of the lblank at the -intended lines. Accuracy in the delivery 'and correct placing of the blank is particularly important 'if the blank is to be gluelessly inter-locked, Vsince itis not only necessary to'fold theblan'kvatithe properlines but it is also necessary y'l-,obring :certain 'edges or cuts treme accuracy inithepo'sitijcnand ladgusturen-1; o-f the` various element" of the ifmacnine'so 'utmost Yin the Conventional via volves minute f veral elements of 'the fgplaeiheit'and nds' is therefore .quite Y emibnai construe,- laborius and rwasteful to Vsettlebetween"ta the die, nori's theie`t1 machine on which'the'abc the folding Of the bllk critical. In lrnacliirie's"o tin. the adjtllb A S procedure. y .A

It is laborious Aand *complicated `si'i'ce :it inv th'eplungervvith respect tothe die, of thefeedmg vine'c'zh'a'riisin"with respect to the plunger and die, and nally, kan adjustment lof vtheinagalli'ne ywithrespect to the feeding vmeclianisiris' and-to` the plunger and die.

It is diilicult and wasteful sinceit'is-frequently insuflicient to adjust and test'thejmachine Vduring trial runs atreduced speed, sirieat theextremely rapid rates of movement o f themachine-parts and of the blank 'masfsand ni1 1 er tia ,o fD the machine elements `and of the blank aiect the operation to such an extent yas to mak-e trial runs at reduced speedunreliable.` Trial 'runs at Ynormal high vproduction speed, on the other hand, involve considerable spoilage and consequent expense.

lThe present invention provides improvements which eliminatethe necessity ofmaking the above mentioned critical adjustments every time a 'box machine isset up `for a new runu requiring afdie plunger and magazineof different size. According to the invention Vthe critical elements of the machine are onceadj usted by the'inachine manufacturer, who of courseiha-s -specially'trained and experienced mechanics able to make the necessary adjustments in a fraction of -the time which the average vshop mechanic of a -box manufacturer would require. The elements of the -machine which have to be exchanged-for yproduction of a different sizebox are delivered to the boxmaker in-sets or units, which are so arrangedthat after installation all the elements automatically assume their correct present position. Once the set vof elements is-installed, themachi-ne is ready for operation at normal Speed Without `any preliminary trial run 'or further adjustments.

Thus `the change-'over time is greatly reduced, machine time is fsaved, lwaste isv eliminated, and the installation of the .various `elements of the aforementioned iset b'rotl'g'lrt within the skill of the ordinary-shop mechanic.

The various objections, features, 4and -advantages ef Athis invention will `appear .more fully from thedetail'ed'description which follows acicompanied by drawings showing, for the purpose of illustration, a preferred embodiment of the invention. 'I'he invention also consists in certain new and original features of construction and combination of elements hereinafter set forth and claimed.

Although the characteristic features of this invention which are believed to be novel will be particularly pointed out in the claims appended hereto, the invention itself, its objects and advantages, and the manner in which it may be carried out may be better understood by referring to the following description taken in connection with the accompanying drawings forming a part of it in which: Y

Figure 1 is a perspective side view of a box machine embodying the present invention, the machine being of the glueless interlocking type shown in a position shortly before the blank feeder picks up a fiat blank at the magazine gate;

Figure 2 is a perspective side view of the box machine of Figure 1 at an advanced phase of its operation at the point when a ,blank is being removed from the magazine by the feeder;

Figure 3 is a perspective end view of the machine at a further advanced phase of its operation at the point when the blank feeder deposits the blank on the folding die; and

Figure 4 is a perspective view in simplified representation of the elements of the set required for changing the box machine for production of a box of different size.

In the following description andV in the claims, various details will be identified by specific names for convenience. The names, however, are intendedto be as generic in their application as the art will permit. Corresponding reference characters refer to corresponding parts in the several :figures of the drawings.

In the drawings accompanying, and forming part of, this specification, certain specific disclosure of the invention is made for the purpose of explanation of broader aspects of the inven tion, but it is understood that the details may be modified in various respects without departure from the -broad Vprinciples of the rinvention and that the invention may beapplied to other structures than the ones'shown.

The folding box forming machine Vshownin Figures 1 -to 3 Yproduces boxes by folding a blank and interlocking thevbox corners in a manner to form a rigid'self-s'ustaining box without gluing, stapling, or riveting. Gluelessly interlocked boxes are quite popular because o f their low cost, the high rate at which they can be set up and because of the low cost and relatively small size of the machine required for setting them up. The glueless interlock of such boxes generally comprises flaps on the side or end walls which are partially inserted throughA cuts or apertures in the end or side walls of the box, respectively. The flaps generally engage the walls in edge-toedge contact, whereby a strong interlock is produced comparable in strength to a glued connection.

Because of the extensive use of gluelessly interlocked boxes a detailed description of a representative blank and box may be dispensed with. It may be stated however that the illustrated machine is particularly equipped to set up and lock boxes of the type disclosed in the patent to Meller No. 2,580,181, dated December 25, 1951.

The machine comprises a supporting framework I to which a base II is secured by bolts I2.

A drive shaft I3 carrying a chain gear I4 is mounted in bearings I5 and I6. The drive shaft 'fitting into holes 54 of a back is driven through a chain II from a motor or other suitable source of power (not shown) and carries a crank I8. A connecting rod I9 connects the crank IS with a crosshead 2l) vertically movable on posts 2l and 22 of the base II The crosshead 20 has a plunger 23 attached to it, movable through the forming and folding aper-ture 24 of a die 25. The plunger 23 has a head portion 25 with two tapped holes 2'I and 28 in it into which bolts 29 ft. The bolts 29 extend through holes 3Q in the crosshead 2E) with close tolerances so that the plunger assumes a definite position with respect to the crosshead when being secured thereto by the bolts. It has been found that this manner of atta-chment is sufficiently positive to make the use of additional dowel pins unnecessary. The bottom surface 32 of the plunger 23 is approximately equal in size to the bottom panel of the box to be formed. The bottom surface of the plunger engages a blank placed over the die aperture and forces it through the die while the inner side walls 33 of the die fold the Vwall panels of the blank towards the outer wall surfaces of the plunger. The plunger is equipped with projectable and retractable elements 35 on the lower ends of levers 36 pivoted in the plunger at 37. 'The levers 36 carry rollers 38 which cause the levers to swing inwardly when the rollers 38 strike projecting cam surfaces 39 in the die (see Figure 4). This causes the elements 35 to be pulled inwardly to perform a certain locking operation on the blank. A detailed description of these box assembly operations is not required for an understanding of the particular improvements provided by this invention.- However, a detailed explanation may be found in the patent to Pagendarm No. 2,580,189, dated December 25, 1951. The folding die 25 proper has two holes 39 tting with close tolerance over `bolts 40 in the base. The bolts serve as dowels and cause the die to assume a definite position with respect to the base II and also permit the die to be securely fastened to the base by nuts 4I. This arrangement causes thedie positively to assume a non-adjustable positionrin the machine in proper relation with respect A,to the path of the plunger. The described mounting causes the central axis of the plunger to coincide with the center axis of the die, the imaginary vertical line extending through the center Vof the die aperture.v

The base I I has a rigid gate supporting plate 42 attached to it which near its upper end carries two dowel pins 43 and a central tapped aperture into which a bolt'44 ts. A magazine gate 45 is removably attached to the supporting plate 42. The gate comprises a horizontal plate or bar 46 having a central hole 41 for the bolt 44 and two holes 48 to receive dowel pins 43. Vertical spaced inner arms 49 carry dowel pins 50 at their upper ends over which blank supporting rods 5I fit. The rods, in turn, t cut-out or recessed portions 3| of a stack 52 of blanks B and align the blanks with respect t0 the magazine gate 45.v The far ends of the rods 5I also carry dowel pins 53 plate 55.' The back plate 55 supports the far end of the stack in a similar way as the magazine gate 45. As shown in Figure 4 the back plate has further holes 56 for dowel pins and a central hole 5'! through which a securing bolt 58 may be inserted to hold the back-plate 55 in place relatively to the framework |0 of the machine.

Vertical outer arms 59 .of the magazine gate carry blank retaining plates 60. The blank retaining plates are secured to the arms 59 by bolts V.pulling it away from 6l and are spaced from each other slightly less than the width of the blanks B.. Thus the retaining plates' prevent .theblanks in .the magazine from falling .out under the pressure'of a feeder arm .'62 urging the blanks towards the gate. The feeder arm 62 is supported by a carriage 63 which runs on a prismatic track 64 and bears against the rearmost .blank to .feed the entire stack of blanks towards the magazinegate.

The spacing .of the .retaining lplates 60 permits removal of the frontmost blank by grasping the blank intermediate the retaining -plates and the stack of blanks in the magazine. This causes the frontmost blank to flex slightly `and .to snap with its .side edges past the-edges of the retaining p1ates66.

The blank feeder mechanism comprises a feeder arm 65 carrying a pairof suction cups `6.6. The feeder .arm 65 is hollow and serves as .a suction duct to Vapply.atproper intervals a partial vacuum to the suction cups. The feeder armhasa flexible duct 6.1 attached .to its end at 66.. The .arm is rigidly mounted on a bracket ..69 having anelongated'guide-way 18 engaging rthe cylindrical outer surface of a ball bearing 1 I. is mounted .on a stud 12 on vasupporting plate or post 13 which, similar' to .the gate supporting plate 42, is rigidlyand permanently attached to the base Il.

The bracket 69 of the feeder arm 65 is pivotally connected to onearm of a bell crank lever 14 at 15. The bell crank lever 1.4 is pivotally mounted on the supporting plate 13 at 16. It has two arms, the one arm 11 being represented by thedistance between the pivotal axes 15 and 16, l 'l being represented b-y the distance between the pivotalaxis 16 and the axisof a pin 19 at which one end of a connecting rod 80 is attached tothe bell crank lever.

The other end of the connecting rod 6i) is pivotally connected to a rocking lever BI at 82. The rocking lever 8l is pivoted in the framework I6 ofthe machine about an axis V8? and carries a cam follower 84 urgedagainst the periphery of a cam 85 on the drive shaft I3. VThe rocking lever 8| is under the action Of helical compressed springs 86 bearing with its oneend against the rocking lever proper and with the other end against a bracket 81 secured 'to .the framework l0.

The cam 85 causes the rocking lever 8l its axis. This, in turn, causes 14 to oscillate about its pivot feeder -arm 65 in a manner presently scribed.

Beginning with the position of the elements of the machine, as shown B rests on the folding die 25, is on its downward stroke driven by theerank i8 moving in a clockwise sense. The rocking its lowermost position as the cam follower 84 is climbing onto portions of lthe cam of progressivell increasing radius. The feeder arm 65 is in front of the magazine gate and the suction cups 66 are only a shortdistance from the frontmost blank, Vmoving towards the blank in order to grip it. As the follower 84 of the rocking arm 8l continues to climb with resoest t0 the cam the yrocking lever is depressed further causing the bell .crank lever i4 to turn cfunterlockwiselr until the suction cups sa make. contact with the front-most .blank of the stack" 52.-. 1

i. ,It will 'be .observed ,that et is fast on the'drive shaft l`3 and to oscillate about the bell crank lever 16 to move the to be deand the plunger 23 lever 8l is nearing this .peint the The `ball bearing 1l g l in Figure 1., a blank n lfollower 84. In distinction,

ythe suction cups Yfrontmost blank. As the cam follower 4continues ,moving the suction motion of the feeder yniechanisrn is relatively slow due to the vert1 gradual @angeln-.curvature of .the lcam at .the .point ofcontact `with the the Vmovement, .of y.the plunger 23 is relatively rapid as the plunger approaches the die .25. Y

Referringnow to yFigure ,2 showing the machine at a phase of .operatior'l advanced .approximately degrees, in terms of' crank angle. it will be seen that the I,plunger has forced the :blank pre- .viously resting on the .die entirely through the die, performing the folding-.operation on the blank, and has .begun to return towards its up.- per dead .center position.

The lcam follower ..84 has just moved .over

the highest Vportion ofthe -Cam ythereby kcausing 66 to make contact with the to move onto ca-m portions .of progressively shorter radius, the rocking lever 8l ymoves upwardly under .the action of .the ,spring -86 and thelbell crank lever 1.4 turns ina clockwise sense thereby i l .cups to the right. This causes the frontmost vblank .toiiex and to snap past the edges of the retaining plates 6.6. Fig.- ure Y2 illustrates the instant at which the right side edge has cleared the retaining` plate, whereas the upper portion of the left side'edee of the blank is still in engagement with therespective retaining plate.

The suction cups with ablank attached to them now swing towards the die as the pivotal axis 15 of the feeder bracket 69 moves Vabout the pivotal axis 16 of the bell crank lever. `During the latter phase of movement the Yrocking lever 8| approaches its uppermost position as the cam follower 84 gradually moves onto the portion of the cam having the lshortest radial distance'from the drive shaft axis.

Simultaneously the crank I8 which operates the plunger 23 `moves towards its upper dead center position causing the Vplunger to clear the die so that Athe feeder candeposit the bla-nk on the upper die surface underneath the plunger.

Figure 3 shows the machine :with the crank I8 at the upper dead center position. At this phase the feeder arm 65 has reached a vertical position vready to deposit the 4plank on the die. The point of. release is controlled by a valve 88 in the duct 61 which at the proper ,moment .shuts olf the duct from the vacuum line 89 and vents it to the atmosphere. The blank now drops onto the receiving surface of the dir-i.v

Removal of the blank from the suction cups is assisted by two flat strippers -96 of flat spring bronze, or spring steel mountedon posts 9| of the die. During thelast portion of the feeding movement the feeder moves the blank past the lower ends of the strippers '.90 which then flex slightly inwardly toengage the upper surface of the blank and retain it on the die. The strippers thus prevent the blank from being disturbed -as the suction cups return empty to the magazine.

It is quite evident that the proper functioning of the machine depends on,v an accurate adjustment ofthe plunger with respect: to the die vand also on the'adjustment of the feeding mechanism with respect. to the die and to the magazine. The proper relationship between these elements must therefore be established every time the machine ischanged topproduce a box of a different size.

The invention simplifies theV changeover from one box sizefto anotherand eliminates thenecessity of making individualladiustments Vby .the

'peculiar design Vconstruction which.l reduces the entire changeover,k operation to a simple exchange of afew elements which the manufacturer of the machine furnishes the box V Illakerinnsets Vready for installation. i

One set of elements is shown in Figure 4. The set includes a die 25 and a plunger-23 tolt it. It further includes a magazine gate 45 and a feeder arm 65 with properly spaced suction cups. As previously described-the plungerassumed its correct position with respect ,to the crosshead 20 by attaching it to the'crosshead by bolts 29. The die 25 is properly centeredby placing it over the bolts 40 thus bringing the -Aaxis of the die into proper relationship with respectgtothe axis of the-crosshead 20 and ofthe plunger 23 .V I Ihevmagazine Ahas a substantially horizontal central axis which, as quite apparent 'from Figure 3, lies in the same vertical plane as thecentral axis of the die and of theplunger. The magazine is automatically aligned by attaching the magazine d'2." The dowel pins 43 prevent any misalignment. The stack of blanks assumes its proper position in the magazine by reason of the rods Sl'tting into diecut recessed portions of the blanks. Y

The feeder mechanism also assumes its proper position by reason of being attachedgto the bell crank lever 14. It Willl be remembered in this connection that the bell crank lever is pivoted to the supporting plate 'I3 and that the ball bearing 1| engaging the guide way v'lll is also mounted on this plate. l

It is, therefore, evident that all the elements of the machine which control the movement and the proper placing of the blank onto the die-are automatically brought into proper relative position by simply attaching these elementsby a few nuts or bolts. V n

The timel consuming Aand Wastefulfadjusting of the machine is, therefore, eliminatedY and the machine is ready for operation at full speed' as soon as a new die plunger, feeder, and magazine assemblyis installed. ,Y i

The invention thus `s implies the change of the machine from one box blank to another, saves machine time, and eliminates Waste. `It furthermore, makes the service of highly skilled specialists familiar with the adjustment of these machines dispensablean'd enablesv the average shop mechanic to perform all the necessary operations Without danger -of maladjustment,

What is claimed is: f f l n 1. A machine for folding into hollow box form flat blanks of foldable sheetmaterial, the machine comprising, a folding die, a plungermovable through said die, a magazine for blanks having a front gate through vwhich the lfrontxnost blank passes, means f-or supportingV a stack of of blanks in a predetermined positionalrelation to said gate, and a suction v,f gri'p'per for removing a blankfrom the magazine at the gate anddepositing yiton the die,` the Vsuction gripper being mounted `for pivotal movement about an axis normal to both themagazine axisandthe die axis, the machine being characterizedY by, and further including, a base having a top surface and an aperture through, which said plunger in movble; `first means on said base and on said folding die, respectively, for removably securing said,Y die on said top surface in a predetermined xed position; and upstanding side bracket on sa.id`-base; a pivotal Abearing vmember on said 'side bracket for said gripper, said pivotal beargate 45 to its supporting plate king member Vbeing fixed onsaid'b'racket inv aV predetermined .xed posiiton With relation to said first means; an upstanding front .bracket on said base for said gate; rand second means 4 onisaid front bracket and on said ,gate for removably securing said gate on said `,front bracket. inV a predetermined fixed position with relation to said first means and said bearing member. whereby the machine may be changed from one box size to another byan exchange of gates and dies Without requiring adjustment of gate and diewith respect to thel suction gripper.

2 Amachine for holding into hollowbox formV flat blanks of foldable sheet materiahthe machine comprising, Ya folding die, va plunger movable through said die, a magazinefor blanks having a front 4gate through which the frontmost blank' passes, means for supporting a stack of blanks in a predetermined positional relation to said gate, and a suction gripper for removing a blank from the magazine at the gate and depositing it -on the die, the suction gripper being mounted for pivotal movement about an axisnormal to both the magazine and the die axis, the machine being characterized by, and further including, a base having a top surface and an aperture through which said plunger is movable; Afirst means on said base and on said folding die, respectively, for removably securing said die on said top surface ina predetermined fixed position; an upstanding side bracket on said base; a pivotal bearing member on said side bracket for said gripper, said pivotal bearing member being fixed on said bracket in a predetermined fixedV position with relation to said first means; an upstanding front `bracket on said base for said gate; a second means on said front bracket and on said gate for removably securing said gate on said front bracket in a predetermined fixed position with relation to said first means and to said bearing member; an upstanding track element on said base; a crosshead slidable on said track element; and third means on-said crosshead and on said plunger, respectively, for removably securing said plunger to said-crosshead in a predetermined fixed relation With regard to said first means, said second means and said bearing member, whereby-the machine may be changed for one box size to another by anl exchange of gates and dies Without, however, requiring adjustment of a replaced gate and die With respect to` the suction Agripper and the path ofthe plunger. n Y g Y 3. A machine for folding into hollow box form flat blanks of foldable sheet material, the machine comprising, a folding die, a plunger movable through said die, a magazine for blanks having a front gate through which the frontmost blank passes, means for supporting a stack-of blanks in a predetermined positional relation to said gate, and aY suction gripper for removing a blank from'the magazine at the gate and depositing it on the die, the suction gripper being mounted for pivotal movement about an axis normal to both the magazinev and the die axis, the machine being'rchar'acterized by, and further including, a base having a top surface and an aperture through which said plunger is` movable; rst means on said base and on said folding die, respectively, for removably securing said die on said top surface in a predeterminedfixed position; anupstanding side bracket on said base; a pivotal bearing member on said side bracket for said gripper, said pivotal bearing member being fixed on said bracket in a predetermined'xed position with relation upstanding front bracket on said base for said gate; and second means on said front bracket and on said gate for removably securing said gate on said front bracket in a predetermined xed position with relation to said first means and to said bearing member; at least one standard mounted on said base normal to said surface; a crossheadslidable on said standard; and third means on said crosshead and on said plunger, respectively. for removably securing said plunger to said crosshead in a predetermined fixed relation with regard to said first means, said second means and said bearing member, whereby the machine may be changed from one box size to another by an exchange of gates, dies and plungers without, however, requiring adjustment of a replaced gate and die with respect to the suction gripper and the path of the plunger.

4. A machine for folding into hollow box form at blanks of foldable sheet material, the machine comprising, a folding die, a plunger movable through said die, a magazine for blanks having a front gate through which the frontmost blank passes, means for supporting a stack of blanks in a predetermined positional relation to said gate, and a suction gripper for removing a blank from the magazine at the gate and depositing it on the die, the suction gripper being mounted for pivotal movement about an axis normal to both the magazine and the die axis, the machine being characterized by, and including, a base having a top surface and an aperture through which said plunger is movable; first means on said base and on said folding die, respectively, for removably securing said die on said top surface in a predetermined fixed position; an upstanding side bracket on said base; a pivotal bearing member on said side bracket for to said first means; an

l0 said gripper, said pivotal bearing member being fixed on said bracket in a predetermined fixed position with relation to said first means; an upstanding front bracket on said base for said gate; and second means on said front bracket and on said gate for removably securing said gate on said front bracket in a predetermined fixed position with relation to said first means and to said bearing member; at least one standard mounted on said base normal to said surface; a crosshead slidable on said standard; third means on said crosshead and on said plunger, respectively, for removably securing said plunger to said crosshead in a predetermined fixed relation with regard to said rst means, said second vmeans and said bearing member; a bell crank lever mounted on said side bracket on a pivotal axis parallel to, and spaced from, said pivotal bearing member, one arm of the bell crank lever carrying said gripper, said gripper also pivotally engaging said bearing member with freedom to slide relatively thereto.

THOMAS R. BAKER. EDWARD J PAGENDARM.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS 

